Read Microsoft Word - 53083-10-IN Flow Switch Installation Manual Rev. C.doc text version

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Released Revised to use RTV securing method for sensor cap Added Plumbing Installation Kit to Section 1.0 Added "IMPORTANT..." to Sec. 3.1 Added Appendix B

07/15/2005 10/06/2005 01/06/05

-JK JK

SENSOR INSTALLATION INSTRUCTIONS

Trimble Mobile Solutions ­ Chantilly, VA

WRITTEN BY: TITLE:

John Kan

TMS ENGINEERING APPROVAL:

53083-10 Dwyer Washout Switch

TMS OPERATIONS APPROVAL: TMS FIELD SERVICE APPROVAL: CUSTOMER APPROVAL:

John Kan

FILENAME:

Dale Sproul

DATE:

53083-10-IN Flow Switch Installation Manual Rev. C.doc

01/6/06

1.0 53083-10 Ready Mix Washout Switch Kit Bill of Materials

Description Washout Switch Extension Cable Washout Switch 35 ft Butt splice connector, 18-22 AWG Butt splice connector, 10-12 AWG Plumbing Installation Kit TMS Part Number 53084 53085 47491 47543 55684-00 Quantity 1 1 4 4 1

2.0 Additional Tools / Materials Needed for Installation

· Teflon Pipe Thread Sealant -- Use Rectorseal T PLUS 2 or similar Teflon based thread sealant, AKA Pipe Dope). NOTE: Teflon Tape should NOT be used. GE Silicone RTV 162 or equivalent Plastic cable ties / tie wraps (2) Pipe Wrenches (2) 9/16" socket drivers Flat head screwdriver or 5/8" nut driver Crimp tool for 18-22 AWG and 10-12 AWG butt splices Wire cutters / strippers Various ¾" pipe fittings such as ¾" x 2 ½" galvanized nipple to replace factory pipe fittings if necessary Electrical Tape 15 inch Crescent Wrench Echo LDX MDT

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3.0 Installation of Washout Switch

· · Reference Figure 1 for Rear Discharge Mixers. Reference Appendix A for Front Discharge Mixers

NOTE: The instructions that follow are specifically for Rear Discharge Mixers, but generally apply to Front Discharge Mixers as well. For special concerns in Front Discharge Mixers please refer to Appendix A at the end of this document.

3.1 Determine Washout Switch Location

The washout switch must be installed in the washout hose line after the Tee fitting on the main water line that splits off the water to the drum and the water to the washout hose. The switch should be mounted in the vertical position as close to the Tee as possible and after the shut off valve in the washout hose line. If the truck has two washout hoses, the switch must be placed in a location that will allow it to trigger when either of the two hoses is used. IMPORTANT: If the heat shrink or cable portion of the washout switch appears to interfere with the vertical pipe, rotate the washout switch slightly off vertical to allow the cable to clear the pipe. The picture below shows a typical finished installation with all parts identified. THE WASHOUT SWITCH WILL BE MOUNTED TO THE PIPES WITH THE CAP OFF. THE CAP WILL BE ATTACHED AFTERWARDS (SEE SECTION 4.1).

Tie-wrap securing washout switch cable

Vertical Pipe

Washout shutoff valve and ¾" nipple

Main Water Line Tee

Washout Switch

Washout Hose

Direction of Water Flow in blue

Note how Washout Switch is angled slightly so its wire will clear vertical pipe. Figure 1 Typical Washout Switch Installation ­ Rear-load trucks

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3.2

Orientation of the Washout Switch and Cap

The washout switch is marked with an arrow on the switch head. When installed this arrow MUST point in the direction of water flow. This arrow location is indicated in Figure 2 below.

Washout Switch Orientation Arrow. Direction of water flow through the switch MUST match this arrow.

Figure 2 Washout Switch Orientation

If the washout switch Body (with vane) must be replaced then the switch cap must be removed first from the washout switch body to prevent it from being damaged. To remove the washout switch cap, remove the tie-wrap around it and then use a flat head screwdriver to gently lift up the clips on the cap allowing the cap to be removed.

4.0 Installing the Washout Switch Body onto the Truck

CAUTION: Before performing any plumbing on the washout hose water line, the truck water tank MUST be depressurized and the water line should be drained. a) Refer to Figure 1 above for an example of a completed washout switch installation with all parts labeled.

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b) Review the chosen location and make sure there are NO DOORS, SHUTTERS, or LEVERS which can come in contact with the washout switch and damage it. c) Make sure the washout switch cap is removed to prevent damage to it while the body is being installed. Remove it from the brass sensor body by gently lifting the plastic clip tabs (indicated in Figure 3 below) away from the switch body. Be careful not to damage the tabs (lift them only enough to release the cap).

2 plastic clip tabs, one on each side of switch cap

Figure 3 Plastic Clip Tab location d) Before installing the washout switch use the 9/16" socket to unbolt the main water line Tee from the truck pedestal. (If it does not have this type of mount skip this step). e) Use the pipe wrenches to remove the washout hose ¾" nipple, shutoff valve, and hose assembly from the main water line Tee and set these pieces aside. f) Use the pipe wrenches to install the washout switch to the main water line Tee as shown in Figure 1. Apply Teflon pipe thread sealant on all pipe threads before installation to prevent leakage. The washout switch should be mounted in the vertical position or slightly off vertical (see note in Section 3.1 above). g) Use the pipe wrenches to attach the washout hose ¾" nipple, shutoff valve, hose assembly to downstream side of the washout switch. Use Teflon pipe thread sealant before assembly on all pipe threads to prevent leakage. h) Use the 9/16" sockets to fasten the main water line Tee to the truck pedestal. If there is no mounting on the Tee then use the supplied Nylon block with a U-bolt to secure it to the pedestal (may require drilling). i) Pressurize the system and check for leaks.

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4.1 Cap Installation

4.1.1 Place RTV on Cap

Place a thin bead of silicone RTV on the sensor cap as indicated in Figure 4. Do not place any silicone RTV in the center of the cap or small bump on the cap. The small bump can be seen more clearly in Figure 5 below.

Silicone RTV bead Do not place any RTV in the center of the cap. Do not cover small bump with RTV.

Figure 4 RTV Bead Locations

Small Alignment Bump

Figure 5 Small Alignment Bump

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4.1.2 Place cap back on sensor body

Making sure to align the small bump on the cap with the slot in the sensor body, replace the cap on the sensor body. Press down firmly so that the cap is fully seated onto the sensor body and the plastic clips are seated in the groove of the sensor body. Any excess RTV should be forced out of the cap near the plastic clips and can be wiped off. See Figure 6 and Figure 7 below for further details.

Excess RTV can be forced out here. Slot mates with small bump on cap.

Figure 6

Figure 7

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4.1.3 Install Cable Ties

· Place a small amount of RTV sealant around the cap where the large tie-wrap will go. This will keep it from sliding off. Wipe off excess after tie-wraps are applied. Install the cable ties as shown in Figure 8 and 9. The big cable tie wraps all around the cap, while the two small ties (wrapped around the big tie just over each plastic clip) will push the cap's plastic clips against the sensor body. This will help secure the cap to the sensor body.

·

NOTE: This cable ties should be tightened securely.

Big tie alone will not push against the plastic clips because it is held up by the hex edges. Therefore small ties must be added.

Small ties (wrapped around big one) will hold down plastic clips

Figure 8

Figure 9

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4.2 Additional Checks Based on Field Failures

4.2.1 Weather Pack Connector

The Weather Pack connector must be assembled correctly otherwise it may not latch closed. Improper installation or crimping can cause this problem. If there is something wrong with the pins or their crimps the connectors will not latch. Connectors that do not latch will eventually disconnect. Solution: If the Weather Pack connectors do not latch together, then they must be disassembled and repaired. Follow the connector installation procedure exactly in order to avoid this problem. To verify proper installation pay special attention to the force required to latch the two connectors together. The rubber seal causes a moderate force. If there is a problem with the connector, then this force will be greatly increased and in some cases proper latching will not be possible. Do not leave a connector in this condition. Remove the pins and crimp with new pins. Make sure the wire is stripped as per instructions and that the wire is inserted properly into the pins before crimping.

4.2.2 Switch Cap Wire Strain

In several cases the wire exiting the cap interfered with the vertical add-water pipe. These are installations where the washout switch is installed right after the main Tee without a shutoff valve in between. On installations similar to Figure 1 where there is adequate spacing between the washout switch and the main Tee it is not necessary to angle the washout switch in order to clear the vertical addwater pipe, In either case it is recommended to secure the cable to the vertical pipe with a tie wrap to keep it from vibrating around. Solution: Rotate the washout switch tee off of vertical so the wire misses the vertical add-water pipe, allowing it to go out straight. If the nylon mounting block is used, the switch can be moved by placing the flat of the Tee on nylon block. See Figure 10 below. Ensure that the wire is tied down and does not put excessive strain on the switch cap (no tension in the wire). Main objective: Mount and position washout switch so there is no force or pressure acting on its connecting wire. That way the cap will stay in its correct position.

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INCORRECT Wire jammed up against vertical pipe

CORRECT Switch Tee turned slightly so wire clears pipe and goes straight behind it

Figure 10

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4.3 Routing and Wiring the Washout Switch Cable

CAUTION: Before wiring the washout switch or cutting any existing cables, make sure that the CrossCheck power harness has been disconnected from the CrossCheck, and that the truck's ignition is turned off. Connect the washout switch connector to the extension cable connector. Wrap the union of the connectors in electrical tape to prevent concrete dust build up or water intrusion. Tie wrap the connectors out of the way under the pedestal or along the truck frame. Leaving an 18-inch service loop, route the wire ends of the extension cable to the CrossCheck unit in the cab of the truck. Follow factory-wiring paths, where possible, and secure the cable every 6-12 inches as necessary with tie wraps. The extension cable should be wired to the CrossCheck harness with the provided butt splices as shown in Figure 11 below.

Pin 11 IP0 Pink w/ gray CrossCheck Harness P/N 46598 20 AWG red black Pin 4 GND Black/ White *** Washout switch / extension cable connectors joined * 2 wire extension cable P/N 53085

Washout Switch P/N 53084

Indicates connection point Two butt splice connectors required

Figure 11 Electrical Wiring for the Washout Switch Note 1: CrossCheck GND (pin 4) needs to be shared with the Water Added Sensor and Drum Rotation Sensor. Note 2: For installations where an existing washout switch is being replaced, you should use the Extension cable P/N 53085, but cut this cable about 18" from the connector. Splice the shortened extension cable into the existing washout switch cable using butt splice connectors and wrap the spliced area with electrical tape. If the existing cable is a 3wire cable, tape off the RED power wire and leave it disconnected. Connect the Extension cable black wire to the existing black wire, and the Extension cable white wire to the existing white wire. * The connectors used are Delphi Part Numbers 12015792 (receptacle on washout switch) and 12010973 (plug on extension cable side) ** The wire color for Pin 4 (Sensor Ground) was changed on the CrossCheck Harness P/N 46598. On revision A, the color is Black. On revision B or C, the color is Black/White.

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5.0 Washout Switch Testing and Verification

1. The water tank must be least half full and pressurized to a maximum of 60 PSI. 2. Check the washout switch assembly for water leaks. 3. Check to see that the CrossCheck is seeing washout events as follows. 4. Press the Red Circle button eight times on the MDT to enter engineering screen. 5. Press the White Down Arrow key twice until the "CPU JOBS INPUTS" screen appears. 6. Press the Red Down arrow until the INPUTS screen is highlighted as shown in Figure 12 below.

White Down Arrow

Washout Switch

Red Down Arrow

CPU JOB INPUTS screen with INPUTS screen highlighted Figure 12 Inputs Screen

Red Circle Button

7. Verify that with the washout hose OFF that the washout switch input reads `1' as shown in Figure 12. 8. Turn on the washout hose and verify that while on the washout switch input reads `0'. 9. Turn off the washout hose and verify that the washout switch input returns to `1'.

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Appendix A Front Discharge Mixer Installation Concerns

In general the washout switch is installed in the same manner in front discharge mixers as in rear discharge mixers. The instructions in the main body of this document should be followed as closely as possible for front discharge mixers with the following exceptions noted in this Appendix. 1. Washout Switch Location For front discharge mixers the washout switch should be installed after the wash out hoses split off from the water line to the mixer drum and before the washout shut off valve. While multiple washout hoses are uncommon on rear discharge mixers, front discharge mixers almost always have more than one washout hose. Care must be taken to install the washout switch in a location so that using either washout hose will trigger the washout switch. Refer to Figure 13 below for an example of a washout switch installed on a front discharge mixer.

Direction of water flow shown in blue

Main water line Tee Split for water added to drum and washout hoses.

Split for Washout Hose #1 and Washout Hose #2

Washout Switch (mounted in as close to vertical orientation as possible)

Main water line from water tank

Figure 13 Front Discharge Mixer Install Location 2. Routing the washout switch cable The standard extension cable provided is 35 feet in length. For front discharge mixers there will be a lot of excess cable. After you route the extension cable to the CrossCheck unit in the cab, cut off the excess length of cable and discard it.

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Appendix B Disassembly and Assembly of Washout Switch Body (if necessary)

The washout switch parts are shown in Figures 14, 15, and 16 below. NOTE: In most installations disassembly of the switch body will not be necessary. However failed sensors may require removal. To remove the washout switch body use a crescent wrench to unscrew the body from the brass Tee fitting. This is necessary in order to check the water vane operation.

Tee Fitting and Washout Switch Body (with Vane)

Figure 14 Washout Switch Body removed from Tee Fitting

Dimple

Slot Figure 15 Washout Switch Cap Figure 16 Washout Switch Body

When reinstalling the washout switch body use Teflon pipe sealant on the threads and make sure that the directional arrow on the body is aligned with the Tee fitting as shown in Figure 2 above. When reinstalling the washout switch cap make sure that the dimple in the cap is aligned with the slot in the washout switch body. Be sure to reinstall the RTV adhesive and the retaining tie wraps (see Sections 4.1.1 and 4.1.3).

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